Shoe sole and method of manufacturing same

ABSTRACT

A shoe including a shoe sole and a method of manufacturing a shoe sole are disclosed. The sole includes a sole body possessing a rear section, a midsection, and a front section. The sole further includes a rear cavity at the rear section, an arched portion at the midsection, and a front cavity at the front section. A first cushion is located at or inside the rear cavity and possesses a first hardness. A rigid member is located at the arched portion of the midsection. A second cushion is located at or inside the front cavity and possesses a second hardness greater than the first hardness. The sole optionally includes flex grooves along a bottom portion of the front section.

TECHNICAL FIELD

The present disclosure relates to a shoe including a shoe sole, and moreparticularly, to a shoe sole configured to maximize comfort, stabilityand energy return during the stages of foot movement during walking,trail hiking, running, and the like, and further to a method ofmanufacturing the shoe and sole.

BACKGROUND INFORMATION

A typical walking movement includes a landing phase, aneutral/transitional phase, and a lift-off phase. The user's heelimpacts the ground during the landing phase. The user's weight is thenshifted forward at the neutral/transitional phase as the user preparesfor the lift-off phase, during which the user's weight is concentratedat the midfoot/arch region. Finally, the forefoot area is activatedduring the lift-off state. Shoes typically contain foam materials andthe like to absorb the impact of the user's foot on the ground.Conventional shoe designs however do not adequately account for the roleplayed by the three core stages of the user's foot during the naturalwalking gate. The present disclosure is directed in part to assisting inthe perambulatory processes by providing for cushioning, stabilizing,and energy return (propelling) during the various stages of walking,trail hiking, running, and the like.

SUMMARY

A shoe and shoe sole are disclosed. The sole comprises a sole bodypossessing a rear section, a midsection, and a front section. The solepossesses a top portion and a bottom portion. In certain embodiments,the sole further includes a rear cavity at the rear section, anoptionally arched portion at the midsection formed such that a bottomsurface of the sole body is substantially concave at the midsection, anda front cavity at the front section. A first cushion is located insidethe rear cavity and possesses a first hardness. A rigid member islocated at the midsection. A second cushion is located inside the frontcavity and possesses a second hardness that may in preferred embodimentsbe greater than the first hardness. The shoe comprises theaforementioned sole and an upper attached directly or indirectlythereto. As used herein, the term shoe may generically refer to anyarticle of footwear that has a sole.

A method of manufacturing a shoe and sole is disclosed. The methodcomprises forming a sole body possessing a rear section, a midsection,and a front section. The sole body includes a rear cavity at the rearsection, an arched portion at the midsection shaped such that a bottomsurface of the sole body is substantially concave at the midsection, anda front cavity at the front section. The method further comprisesplacing a first cushion inside the rear cavity, the first cushionpossessing a first hardness, placing a rigid member at the archedportion of the midsection, and placing a second cushion inside the frontcavity. The second cushion possesses a second hardness that in preferredembodiments may be greater than the first hardness.

BRIEF DESCRIPTION OF THE DRAWINGS

Other features and advantages disclosed herein will become more apparentfrom the following detailed description of exemplary embodiments whenread in conjunction with the attached drawings, wherein:

FIG. 1 is a schematic illustration of an exemplary embodiment of a sole;

FIG. 2 is a schematic cross section of the heel area of an exemplaryembodiment of a sole coupled to a shoe upper;

FIG. 3 is a schematic illustration of another exemplary embodiment of asole;

FIG. 4 is a schematic illustration of another exemplary embodiment of asole;

FIG. 5 is a schematic illustration of an exemplary embodiment of a shoeincluding a sole; and

FIG. 6 is a schematic illustration of another exemplary embodiment of ashoe including a sole.

DETAILED DESCRIPTION

FIGS. 1, 3 and 4 show an exemplary embodiments of a sole 100, whichincludes a sole body 110 possessing a rear section 112, a midsection114, and a front section 116. The sole 100 further includes a rearcavity 122 at the rear section 112, an arched portion at the midsectionformed such that the top surface of the sole body 110 is convex and/orthe bottom surface S of the sole body 110 is substantially concave atthe midsection 114, and a front cavity 126 at the front section 116. Thesole further includes a top portion 1101 and a bottom portion 1102. Afirst cushion 132 is located at or inside the rear cavity 122 andpossesses a first hardness. A rigid member 134 is located at the archedportion of the midsection 114. A second cushion 136 is located at orinside the front cavity 126 and possesses a second hardness. Inexemplary embodiments, the second hardness is greater than the firsthardness. In exemplary embodiments, the second cushion 136 is bouncierthan the first cushion 132. In exemplary embodiments, the rigid member134 is substantially harder than the first and second cushions 132, 136.In exemplary embodiments, the rigid member 134 is substantially rigid orsemi-rigid and in preferred embodiments may have a hardness greater thanthat of the first cushion 132 and the second cushion 136, individuallyor combined. In exemplary embodiments, the rigid member 134 is locatedwithin or upon a middle cavity 124, which may be located on the topportion 1101 (see FIG. 3) or the bottom portion 1102 (FIGS. 1 and 4) ofthe midsection 114. In exemplary embodiments, plural rigid members areplaced at the midsection 114 in or on the top or bottom portions.

In exemplary embodiments, the rear section 112 supports the heel area ofthe foot of the user, and is configured to absorb the impact made duringwalking, hiking, running, or the like, when the heel strikes the ground.The first cushion 132 located at the rear section 112 allows for asofter heel landing, thereby potentially reducing stress on the joints,knees and back of the user.

In exemplary embodiments, as the foot of the user transitions from heelimpact to a more neutral state, the rigid member 134 provides archsupport, promotes stability, and prepares and supports the foot of theuser for the next phase in the walking, hiking, or running motion. Themidsection with its rigid member 134 allows for stable and smoothtransition between the immediate heel strike and the forefoot lift-offphase of the walking, hiking, or running motion. The rigid member 134 isproportioned and configured so as to reduce rolling and preventcollapsing of the foot, thus reducing pain and the amount of work neededto move forward. In exemplary embodiments, the rigid member 134 ismanufactured in a very dense compound for desirable arch support, forexample nylon or thermoplastic polyurethane. In FIGS. 1 and 4, the rigidmember 134 is inserted from the bottom, and in FIG. 3, the rigid member134 is inserted from the top. The rigid member 134 supports the foot andprevents the arch from collapsing, therefore stabilizing the foot as ittransitions forward to the final portion of the walking gate.

In exemplary embodiments, the front section 116 supports the forefootarea, and is configured to propel the foot forward. The hardness andpositioning of the second cushion 136 promotes energy return, thuspotentially producing a bounce or propel sensation, which may or may notbe perceptible to the user, during the thrust phase of the walking,hiking, or running motion.

In exemplary embodiments (see FIGS. 1 and 3), the rear cavity 122 andthe front cavity 126 are open to a top surface of the sole body 110. Incertain embodiments, an insole may cover the top surface of the sole,and be considered as part of the sole disclosed herein. The insole maybe configured with section to further aid in the absorption, stabilizingand energy return (propel) advantages of the sole 100.

In various exemplary embodiments (see FIGS. 1, 3 and 4), the rear cavity122 and/or the front cavity 126 can be open or closed to various sidesof the sole body 110, including the upper, bottom, front, rear, andlateral surfaces of the sole body 110. The first cushion 132, secondcushion 136 and/or rigid member 134 may optionally be accessible orremovable through any of the upper, bottom, front, rear, and lateralsurfaces of the sole body 110, such feature being informed by whether acorresponding cavity is open or closed to any one of those surfaces. InFIGS. 1 and 3, both the rear cavity 122 and the front cavity 126 areopen to the top surface of the sole body 110, and are closed to allother sides of the sole body 110. In FIG. 4, the rear cavity 122 is opento the top surface of the sole body 110 and is closed to all other sidesof the sole body 110, and the front cavity 126 is open to the bottomsurface of the sole body 110 and is closed to all other sides of thesole body 110. In such these embodiments, an insole may optionally beplaced substantially abutting (directly or indirectly) the top portionof the sole body 110.

In exemplary embodiments, the rigid member 134 includes an elongatedportion possessing a longer extent along a rear section-to-front sectiondirection (i.e., the major axis) of the sole body 110. The rigid member134 may further comprise a shorter extent along a transverse directionperpendicular to the rear section-to-front section direction of the solebody 110.

In exemplary embodiments, the elongated portion is located against thebottom surface S of the sole body 110 at the midsection 114.

In exemplary embodiments, the sole includes a middle cavity 124 locatedat the midsection 114 and optionally closed to the upper surface and/orto the bottom surface S of the sole body 110, to promote stabilizationof the arch of the foot, and to reduce the risk of collapsing of thearch of the foot. The middle cavity 124 may optionally be located alongthe top portion of the midsection 114. The rigid member 134 is locatedat or inside the middle cavity 124, as illustrated by the dotted line inFIG. 5. In an exemplary embodiment, the rigid member 134 includesinjected nylon, thermoplastic polyurethane, and/or steel. In FIGS. 1 and4, the middle cavity 124 is open to the bottom, and in FIG. 3, themiddle cavity 124 is open to the top.

In exemplary embodiments, the rear section 112 includes a suspendedmiddle portion 1121 (shown in FIG. 2) between two lateral portions 1122.The lateral portions 1122 extend further than the suspended middleportion 1121 in a top-to-bottom direction of the sole body 110.

In exemplary embodiments, the suspended middle portion 1121 furtherallows for a softer heel landing, thereby further reducing stress on thejoints, knees and back of the user. This structure may also provide asofter sensation at the user's heel area. In an exemplary embodiment,the two lateral portions 1122 touch the ground during the process ofwalking. Alternatively, the two lateral portions 1122 may be separatedfrom the ground by outsole portions 1123, as shown in FIG. 2.

In exemplary embodiments, an air pocket 1124 is located above or insidethe suspended middle portion 1121 of the rear section 112. In exemplaryembodiments, the air pocket 1124 further allows for a softer heellanding, thereby further reducing stress on the joints, knees and backof the user. For example, the air pocket 1124, along with the suspendedmiddle portion 1121 of the rear section 112, creates a comfortablelanding area wherein the air pocket 1124 allows for freedom of movementdown for the heel, and cantilevered heel portions on either sides of thesuspended middle portion 1121 can splay/flares out, as illustrated forexample by the white arrows in the sectional X-X view in FIG. 3. Thisallows for a softer heel landing, thereby further reducing stress on thejoints, knees and back of the user, for example during the initial heelstrike of the walking gate. For example, the first cushion 132 locatedat the rear section 112, the air pocket 1124 and the cantilevered heelportion design, can together allow for a softer heel landing, therebypotentially reducing stress on the joints, knees and back of the user.

In exemplary embodiments, the suspended middle portion 1121 issubstantially oval in shape when viewed from the bottom. In otherembodiments, the suspended middle portion 1121 may be circular orsubstantially rectangular in shape without deviating from thedisclosure.

In exemplary embodiments, the front section 116 may have flex grooves1161 along the bottom portion of the sole body 110. In preferredembodiments these flex grooves 1161 are disposed along the bottomportion of the front section 116 in a substantially lateral direction,perpendicular to the major axis of the shoe sole. The flex grooves 1161may additionally or alternatively be present on the bottom portion ofthe front section 116 in a direction parallel to the major axis of theshoe sole, and/or may be further disposed in such directions as mayfacilitate or enhance the deformation of the shoe sole in directionsthat would complement contemplated foot movements encountered duringexercise, hiking, cross training, running, climbing, etc. Flex grooves1161 can be formed on the sole body 110 and/or on the second cushion136. The combination of the flex grooves 1161 and the second cushion 136creates desirable propulsion effects during walking and other exerciseactivities.

In exemplary embodiments, the bottom surface of the shoe sole mayinclude striations 1125 that are positioned so as to complement thefunctions (absorb, stabilize, propel) of the various portions of theshoe sole. In certain embodiments, such striations 1125 in the frontsection 116 may be substantially perpendicular to the major axis of theshoe; in the midsection 114 may be substantially radially disposed inrelation to the midpoint(s) of the lateral edges of the midsection 114;and/or in the read section 112 may be disposed substantially radially tothe midpoint of the rear section 112 or center of curvature of thesuspended middle portion 1121.

In exemplary embodiments, the rigid member 134 includes nylon. In anexemplary embodiment, a nylon rigid member 134 at the midsection 114further promotes stability.

In exemplary embodiments, the first cushion 132 includes compressionmolded ethylene vinyl acetate (EVA). In exemplary embodiments, thecompression molded EVA cushion at the rear section 112 further allowsfor a softer heel landing, thereby further reducing stress on thejoints, knees and back of the user.

In exemplary embodiments, the first cushion 132 includes 55-60 degreeEVA. In an exemplary embodiment, the 55-60 degree EVA cushion at therear section 112 further allows for a softer heel landing, therebyfurther reducing stress on the joints, knees and back of the user. Inexemplary embodiments, the first cushion 132 is formed of the samematerial as the sole body 110. In exemplary embodiments in which thesole body 110 is injection molded, the first cushion 132 is integrallyformed with the sole body 110 and does not exist as a separate component(see FIG. 6). In exemplary embodiments, one purpose of the first cushion132 is to close, and thereby form, the air pocket 1124 at the rearsection 112.

In exemplary embodiments, the sole body 110 is made of EVA, ethylenepropylene (EPR), polyurethane, and/or rubber, or any suitable materialsknown in the art.

In exemplary embodiments, the second cushion 136 includes elastic EVAfoam. In an exemplary embodiment, the elastic EVA foam cushion at thefront section 116 of the sole body 110 includes 55-60 degree EVA. In anexemplary embodiment, the elastic EVA foam cushion at the front section116 of the sole body 110 includes EPR. In an exemplary embodiment, theelastic EVA or EPR foam cushion at the front section 116 of the solebody 110 further promotes energy return during the thrust phase of thewalking motion. In exemplary embodiments, the second cushion 136 isarranged and configured to align with the user's metatarsal bones.

In exemplary embodiments, the first cushion 132 and second cushion 136maybe be substantially rectangular or trapezoidal when viewed from thetop or bottom, with the sides and/or edges of the rectangular shapesbeing optionally rounded. In exemplary embodiments, the top and bottomsurfaces of the first cushion 132 and second cushion 136 may besubstantially flat, or may be curved so as to allow for their topsurfaces to receive the curvature of the foot and/or insole. In certainembodiments, the bottom surface of the second cushion 136 may optionallyinclude lateral projections disposed in a direction perpendicular to themajor axis of the sole, as shown in FIG. 1. The first cushion 132 andsecond cushion 136 may be shaped and/or proportioned so as to maximizeenergy return with design constraints and materials cost considerations.

In exemplary embodiments, the second cushion 136 includes 45 degree EVA.In an exemplary embodiment, the 45 degree EVA cushion at the frontsection 116 of the sole body 110 further promotes energy return duringthe thrust phase of the walking motion.

FIG. 5 shows an exemplary embodiment of a shoe 300 including a sole 100and an upper 200. The upper 200 is configured to receive the foot of auser. The sole 100 is coupled directly or indirectly to the upper 200such that a heel portion of the foot is supported by the rear section112 of the sole body 110 and a forefoot portion of the foot is supportedby the front section 116 of the sole body 110.

In exemplary embodiments, the shoe 300 includes an outsole 250 coupledto the sole 100 such that the sole 100 is located between the outsole250 and the upper 200. The shoe 300 may optionally further comprise aninsole. It will be appreciated that the sole 100 disclosed herein may bea midsole between an outsole and an insole, or may include one or moreof an outsole or insole, integrally or via attachment, without deviatingfrom the present disclosure. An exemplary embodiment of an insoleincludes a 360 degree EVA insock. The combination of the sole and theinsock creates desirable propulsion effects during walking and otherexercise activities.

An exemplary method of manufacturing a shoe and sole comprises forming asole body 110 possessing a rear section 112, a midsection 114, and afront section 116. The sole body 110 includes a rear cavity 122 at therear section 112, an arched portion at the midsection 114 shaped suchthat a bottom surface S of the sole body 110 is substantially concave atthe midsection 114 and/or a top surface of the sole body 110 issubstantially convex at the midsection 114, and a front cavity 126 atthe front section 116. The method further comprises placing a firstcushion 132 at or inside the rear cavity 122, the first cushion 122possessing a first hardness, placing a rigid member 134 at the archedportion of the midsection 114, and placing a second cushion 136 at orinside the front cavity 126. In exemplary embodiments, the secondcushion 136 possesses a second hardness greater than the first hardness.In exemplary embodiments, the second cushion 136 is bouncier than thefirst cushion 132.

It will be appreciated by those skilled in the art that the disclosureherein can be embodied in other specific forms without departing fromthe spirit or essential characteristics thereof. The presently disclosedembodiments are therefore considered in all respects to be illustrativeand not restricted. The scope of the invention is indicated by theappended claims rather than the foregoing description and all changesthat come within the meaning and range and equivalence thereof areintended to be embraced therein.

What is claimed is:
 1. A shoe comprising a shoe sole comprising: a solebody possessing a rear section, a midsection, and a front section; arear cavity at the rear section; an arched portion at the midsection. afront cavity at the front section; a first cushion located at or insidethe rear cavity and possessing a first hardness; a rigid member locatedat the arched portion of the midsection; and a second cushion located ator inside the front cavity and possessing a second hardness, the secondhardness being greater than the first hardness.
 2. The sole of claim 1,wherein the rear cavity and the front cavity are open to a top surfaceof the sole body.
 3. The sole of claim 1, wherein the rigid membercomprises an elongated portion possessing a longer extent along a rearsection-to-front section direction of the sole body.
 4. The sole ofclaim 3, wherein the elongated portion is located against a bottomsurface of the sole body at the midsection.
 5. The sole of claim 3,wherein the sole includes a middle cavity located at the midsection andclosed to a bottom surface of the sole body, and the rigid member islocated at or inside the middle cavity.
 6. The sole of claim 1, whereinthe rear section includes a suspended middle portion between two lateralportions, the lateral portions extending further than the suspendedmiddle portion in a top-to-bottom direction of the sole body.
 7. Thesole of claim 6, further comprising an air pocket located above orinside the suspended middle portion of the rear section.
 8. The sole ofclaim 1, wherein the rigid member includes nylon.
 9. The sole of claim1, wherein the first cushion includes compression molded ethylene vinylacetate.
 10. The sole of claim 1, wherein the first cushion includes55-60 degree ethylene vinyl acetate.
 11. The sole of claim 1, whereinthe second cushion includes elastic ethylene vinyl acetate foam.
 12. Thesole of claim 1, wherein the second cushion includes 45 degree ethylenevinyl acetate.
 13. The sole of claim 1, wherein the front sectionfurther includes flex grooves along a bottom portion of the sole body.14. The sole of claim 1, wherein the sole body includes ethylene vinylacetate.
 15. The sole of claim 1, wherein the sole body includespolyurethane.
 16. The sole of claim 1, wherein the sole body includesethylene propylene.
 17. The sole of claim 1, wherein the sole bodyincludes rubber.
 18. A shoe comprising: an upper configured to receive afoot of a user; and the sole of claim 1 coupled to the upper such that,when the foot of the user is received in the upper, a heel portion ofthe foot is supported by the rear section of the sole body and aforefoot portion of the foot is supported by the front section of thesole body.
 19. A method of manufacturing a shoe and shoe solecomprising: forming a sole body possessing a rear section, a midsection,and a front section, the sole body including a rear cavity at the rearsection, an arched portion at the midsection shaped, and a front cavityat the front section; placing a first cushion at or inside the rearcavity, the first cushion possessing a first hardness; placing a rigidmember at the arched portion of the midsection; and placing a secondcushion at or inside the front cavity, the second cushion possessing asecond hardness greater than the first hardness.